Easily assembled and repairable plastic shipping pallet

ABSTRACT

An easily assembled and repairable plastic pallet that include two or more runner rails (FIGS.  2 &amp; 4 ) and/with multiple plastic cross boards (FIGS.  5 &amp; 6 ) secured perpendicularly to the opposite side rails (FIGS.  2 &amp; 4 ). This construction allows for rapid and easy repair of a pallet (FIG.  1 ) that may become damaged. The plastic cross boards (FIGS.  5 &amp; 6 ) and runner rails (FIGS.  2 &amp; 4 ) are all ribbed out for the sole purpose of lighter weight. The repairable plastic pallet is made of High Density Polyethylene (HDPE) or Polypropylene (PP) in virgin or recycled material along with a foaming agent or a gas to form a stronger and lighter weight pallet. Therefore, not ruling out the uses of other types of materials possibly used in the future.

FIELD OF THE INVENTION

This invention relates to an easily assembled and repairable plastic lightweight shipping pallet.

1. Technical Field

This present invention relates to various shipping pallets and more particularly to an easily assembled and repairable plastic shipping pallet that includes two or more plastic runner rails (FIG. 4) each including multiple top and bottom pegs for board mounting. When two or more plastic runner rails (FIG. 4) are secured to multiple plastic cross boards (FIGS. 5&6) top and bottom you form a pallet (FIG. 1).

2. Background of the Invention

Wooden pallets can be expensive, often break and become unusable after one or more uses, and can create disposal problems. Therefore, it would be desirable to have “my invention” a repairable plastic pallet that could/can be used for multiple uses and if damaged, repaired on site. My invention is a repairable plastic pallet that is recyclable, eliminating a disposal problem. This repairable plastic pallet is durable enough to transport goods from one destination to another worldwide. Also, a forklift and/or pallet jack can be used to lift or move this plastic pallet (unloaded or loaded) from place to place.

GENERAL SUMMARY DISCUSSION OF THE INVENTION

It is thus an object of the invention to provide an easily assembled and repairable plastic pallet (FIG. 1) that includes two or more plastic runner rails (FIGS. 2&4), with multiple top/bottom molded on pegs (FIG. 4) for board mounting (FIGS. 5&6). When two or more plastic runner rails (FIGS. 2&4) are secured to multiple cross boards (FIGS. 5&6) you form a pallet (FIG. 1). Accordingly, an easily assembled and repairable plastic shipping pallet (FIG. 1) is provided.

BRIEF DESCRIPTION OF DRAWINGS

For a further understanding of the nature and objects of the present invention, reference should be made to the following detailed description, taken in conjunction with the accompanying drawings. This drawing is to be used for an illustrated purpose only.

FIG. 1 shows the view of the assembled pallet.

FIG. 2 shows the view of the pallet with no slats/boards on top, and shows mounted on plastic pegs.

FIG. 2A (Added) shows the molded on plastic locking device used to secure board in place. This figure was added because it coincides with FIGS. 5 & 6.

FIG. 3 shows the side view of the pallet.

FIG. 4 shows the top & side view of runner rail, shows notches used for 4-way entry when pallet is assembled, and it shows molded on pegs top & bottom.

FIG. 5 shows board/slat, holes for mounted on pegs to fit into, and locking device slot that is open all the way through.

FIG. 6 shows board/slat, holes for mounted on pegs to fit into, but does not show slot for locking device.

FIGS. 1 through 6 show various aspects of an exemplary embodiment of the easily assembled and repairable plastic shipping pallet (FIG. 1) of the present invention. Easily assembled and repairable plastic shipping pallet (FIG. 1) includes two or more plastic runner rails (FIGS. 2&4) and multiple plastic cross boards (FIGS. 5&6). The preceding description (using FIG. 2-6) show an easily assembled and repairable plastic pallet (FIG. 1) has been provided.

It is noted that the embodiment of the easily assembled and repairable plastic shipping pallet (FIG. 1) described here in detail for exemplary purposes is, of course, subject to many different variations in structure, design, application and methodology. Because many varying and different embodiments may be made within the scope of the inventive concept(s) herein taught, and because many modifications may be made in the embodiment herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.

DESCRIPTION OF PREFERRED EMBODIMENTS

(Added) This section was added to get a better understanding on how to put together and take apart this repairable plastic pallet.

Assembly of the Repairable Plastic Pallet:

“Board/Slat (FIG. 6) will be used in conjunction with runner/rail (FIG. 4) to form an assembled pallet (FIG. 1)”.

Step 1: Refer to Drawing (FIG. 4) of a Runner/Rail.

-   -   A. “I suggest assembling bottom side first”. Take 3 runner/rails         (FIG. 4) placing on a flat surface notch side up.     -   B. Be sure pegs are facing in same direction.     -   C. Only on one end of each runner/rail, the first 2 pegs are         turned in opposite direction than the others. (When the board         (FIG. 6) is mounted this prevents the jarring loose caused by a         the entrance of a forklift or pallet jack).

Step 2: Refer to Drawing (FIG. 6) of a Board/Slat.

-   -   A. The board/slat (FIG. 6) will only go on in one direction.     -   B. Place the board/slat (FIG. 6) on the runner/rail (FIG. 4).     -   C. At this point the pegs on the runner/rail (FIG. 4) should be         flush with top of board/slat (FIG. 1).     -   D. Board/Slat (FIG. 6) should be resting flush on runner/rail         (FIG. 1).     -   E. Now slide board/slat (FIG. 6) with slight force, so that the         molded on locking device shown in (FIG. 2 a not shown in FIG. 2)         is engaged in slot hidden in board/slat (FIG. 6).     -   F. Now board/slat (FIG. 6) is secure & in place.     -   G. Repeat step 2 until all boards/slats are on bottom & then         turn pallet over see (FIG. 2).     -   H. Repeat step 2 until all boards/slats are on top refer to         (FIG. 1)—your assembled repairable plastic pallet.         How to Disassemble the Pallet:

Step 1: Remove a Board/Slat (FIG. 6) from a Runner/Rail (FIG. 4).

-   -   A. To remove a board/slat (FIG. 6) use slight force, push/pull         “depending on the direction of board” in opposite direction.         This procedure will disengage molded on plastic locking device         shown in (FIG. 2 a not shown in FIG. 2).     -   B. Now board is removable.

Step 2: Runner/Rail (FIG. 4) Removal.

-   -   A. To remove a runner/rail (FIG. 4) all boards/slats (FIG. 6)         must be completely removed.     -   B. Now you have a fully disassembled pallet. 

1. This repairable plastic pallet is the first of it's kind.
 2. A. This pallet is made from High Density Polyethylene (HDPE) and/or Polypropylene PP), virgin or recycled material. B. Also, I am using a blowing agent and/or a gas which is all blended together during the injection molding process. C. The blowing agent or gas used in small percentage (%) makes repairable plastic pallet lighter and stronger. D. Other forms of plastic or other materials may sometime in the future be used.
 3. This repairable plastic pallet consists of 2 molded parts. 1) A runner/rail (FIG. 4) 2) board/slat (FIGS. 5&6). 1 A) A runner/rail (FIG. 4) is solid on both ends. B) Ribbed out along both sides to help reduce weight. See FIGS. 1,2 &
 3. C) There are molded on pegs top & bottom (FIG. 4) one of every 2 pegs are slightly larger (not shown in any figures) for correct board mounting. D) There is also a molded on plastic locking device located between each pair of pegs (not seen on FIG. 2, but visible on FIG. 2-A) used to secure board/slat (FIG. 6) in place. E) The height of the molded on locking device is approximate 1/16″, which could increase or decrease. 2 A) A board/slat see FIGS. 5 &
 6. B) Smooth on top (FIG. 1) and ribbed out on bottom (FIG. 2). C) Each board (FIGS. 5 & 6) has holes which are in line with the pegs on the runners/rails (FIG. 1) D) Each hole slightly larger round on each side of board/slat (FIG. 6). One hole “in board/slat” is larger than the other hole “in board/slat” (not really noticeable in FIG. 6) fits over head of peg. (The difference for hole sizes is for assurance of proper board mounting). E) The slightly smaller end of each hole (FIG. 6) is tapered for the head of the peg to rest in. F) The slot for the molded on plastic locking device can be seen on top & bottom of FIG. 5., but only seen from the bottom of FIG.
 6. (Hidden). G) Boards/slats (FIGS. 5 & 6) can be mounted only in one direction. H) After board/slat (FIG. 6) is mounted, molded on locking device secures the board/slat (FIG. 6) into position.
 4. Pallet assembled—FIG.
 1. A) Illustration shows pallet assembled with notched runner/rail (FIG. 1) used with a four-way entry for a forklift. B) A straight runner can be used in the place of a notched runner/rail (FIG. 4). Now the assembled pallet becomes a two-way entry pallet.
 5. This pallet can be shipped either assembled or unassembled depending on customers request.
 6. This pallet is made of 100% plastic blended with a foaming agent and/or gas. A) No heat, screws and/or mechanical screws, clips, lugs, plates, flanges, hinges, bolts, nuts, nails, plastic nails, adhesives, ultra-sonic welding, or press-fitting are necessary for the assembly of this repairable plastic pallet. B) No tools are required for assembling/disassembling of this repairable plastic pallet. C) The only requirements needed to assemble/disassemble this repairable plastic pallet are your hands.
 7. This repairable plastic pallet can be repaired on the job-site, never required to be sent back to the factory for repairs. 